MG Midget Madness (i.e. It was either this or kill it with fire)

[chibikougan]

Doesn't even look like you will have to put the socket on first...Plenty of room.

[GySgtFrank]

Originally Posted by chibikougan

Doesn't even look like you will have to put the socket on first...Plenty of room.

That's what I was thinking, but I have to resist the temptation to stuff anything else in that space.

I've been looking at the fuel system and running into problems, no surprise there. I really hate the dinky 7 gallon fuel tank which was a PITA with the 1500. It's going to be an even bigger pain with the rotary. The fuel mileage I was getting with this engine in the SA was actually pretty good, but you won't get far on 7 gallons regardless. I've been researching fuel cells with integrated FI capable pumps. The 15 gallon Aeromotive cell looks like the best bet. It's 20" W x18" L x 10" Deep properly baffled with the integrated pump. The only problem is that I don't need a pump that will support 1000 HP, Glenn might, but I don't. When I get up the money I'll have to give them a call and see if they can make me a deal on a fuel cell with the cheaper pump. Unfortunately this means rethinking my plans on the exhaust. The fuel cell will eat into the space behind the existing fuel tank for the stock muffler. I was planning to put the new muffler there, but there won't be any room now. I'll probably have to go with a pair of the shorty pre-silencers from RB and try to fit them before the axle, leaving the space beside the tank for the muffler.

Just scratching my head and rambling.

[GySgtFrank]

I got the intake side pretty much done while I'm waiting for my Racing Beat muffler to get here. There was no way to route the intake tract, and no room for the filter, where I was thinking to put it. This was the best I could come up with for now. I may try to build a canister surround and do a cold air pick up for it later. I need to see where everything else [i.e. radiator and shroud/oil cooler(s), etc.] will fit first.

I had to build an adapter to go from the AFM to the standard flange for a 4" ID filter that is 6 inches in diameter and about 6.5 inches in length.

air filter bracket 2 by Kevin Frank, on Flickr


... and pictures of the filter installed.


air filter 1 by Kevin Frank, on Flickr


air filter 2 by Kevin Frank, on Flickr


The flanges are a very tight fit. They just barely clear the water pump pulley. Packaging is very tight in one of these cars.


The muffler is supposed to be here Tuesday. I need to get the placement done on that before I can make any further plans about the rest of the exhaust. It's also going to impact the size and placement of my decision on a fuel tank. Still very much up in the air about what to do about that for now.

[GySgtFrank]

Looking around to see what else I can accomplish while waiting on parts.

I thought it would be appropriate to post these pictures for anyone planning out a similar swap. Fitted my existing spark plug wires to check for fit. I believe these were stock size, but I couldn't swear to it as they came (almost new) on the engine when I bought it. I have plenty of extra for looms so I think that any wires made for the FC RX7 should work.

spark plug wires 1 by Kevin Frank, on Flickr


spark plug wires 2 by Kevin Frank, on Flickr

[chibikougan]

Nice. Lookin Good!

[GySgtFrank]

While I've been waiting for my muffler to get here I have been piddling with a few things. Did some more trimming for the radiator and figured out which one I'm going to try. The VW Scirocco radiator would have fit well in the front opening, but it's a little smaller than I would like. It probably would have been fine, but I get really nervous about over heating a rotary. I looked it over again and checked out what a few others have done. I believe I can fit an off the shelf 15.5 x 31 radiator in there. This will put me just over 400 square inches and is meant to cool an LS V8, so it should do the trick handily (provided I can make it fit of course). It will require a few modifications to the radiator and a lot more modification of the front radiator area, but should be quite a bit cheaper than a custom built radiator.

The other thing I did I would have sworn would not work. I modified the clutch slave line attachment using pieces from both the MG and an old slave cylinder I had from a 12A. I cut off most of the hose portion of the 12A line and drilled it out with a 1/4" drill bit. I then removed the slave cylinder fitting from the MG plastic line, straightened it out, and slipped it into the drilled 12A fitting. I then welded the MG line to the 12A fitting because I was concerned that it may leak otherwise. I shortened the plastic clutch line and heated up the new fitting with a Propane torch. I then inserted the barbed end of the steel MG line fitting back into the plastic line. It needed some cleanup inside the line, but when I hooked it to the original MG master cylinder (filled and purged of course), it worked. It seems to be fully disengaging the clutch and no leaks so far. We'll have to see if it works as well as it appears once it's running though.

a picture of the MG clutch master cylinder hooked to the Mazda clutch slave cylinder.

clutch master by Kevin Frank, on Flickr


and a picture of the Mazda clutch slave with the modified fitting.


clutch slave by Kevin Frank, on Flickr


It's definitely not pretty, but I was not expecting this to work. I thought it was worth a try while I was waiting for parts is all.

[GySgtFrank]

We have muffler.


muffler by Kevin Frank, on Flickr


Now for my next magic trick. Making that big ass muffler fit into non-existent space.

[RETed]

Originally Posted by GySgtFrank

We have muffler.

Now for my next magic trick. Making that big ass muffler fit into non-existent space.

You can always ditch the passenger seat and put it there...

Still got your hearing?


-Ted

[GySgtFrank]

Originally Posted by RETed

You can always ditch the passenger seat and put it there...

Still got your hearing?


-Ted

That's an idea. We don't need no steenkin' passengers.

My hearing is pretty bad, so I'd like to hold onto what I have left. The exhaust system is going to get a little ... umm ... complicated in pursuit of that goal.

[GySgtFrank]

I'm kind of committed at this point.


trunk area - before by Kevin Frank, on Flickr


trunk - cut out 2 by Kevin Frank, on Flickr


trunk - cut out 1 by Kevin Frank, on Flickr

[chibikougan]

You lost your boot sole....

[GySgtFrank]

Originally Posted by chibikougan

You lost your boot sole....

It's outta here! I was cringing a bit when I started making the cuts, but it had to be done to get a decent sized muffler and fuel tank in there.

... and the position where the muffler is going to fit.


muffler position by Kevin Frank, on Flickr


I'm going to lose about 6.5 inches of boot ( ) space due to raising the floor that far. It will allow me to fit the muffler, with plenty of air space around it, and to fit a standard 20 gallon fuel cell (24x20x10) if that's what I end up going with. The bottom edge of the muffler and the fuel cell will project below the car by about 2 inches, but I don't think that should be a problem. It's not a 4x4 and departure angle shouldn't be too big of a worry.

[hades]

Looks good.

[GySgtFrank]

Thanks Jeff. Working on building the box sides that will be flanged at the top.

[GySgtFrank]

Well change 546. After getting the floor out of there I was able to reassess my options. I pulled the FC tank from the SA and fitted it in there. It appears that I can make it work. These things happen when you're making it up as you go along.


fuel tank 1 by Kevin Frank, on Flickr


fuel tank 3 by Kevin Frank, on Flickr


The downside is that I will probably have to use one of the Spin Tech mufflers from the SA behind the tank as they are narrower. They were a bit loud anyway and I can use the RB Muffler in the SA when I get to putting the turbo motor in that. I could use the RB muffler in the MG, but I'm afraid there would be too little air space around it for me to feel comfortable. Especially considering how hot a rotary gets the muffler. It will also necessitate running dual 2" OD pipe to just before the muffler. It's going to be that tight of a fit.

The up side is that I will have the same or better cruising range as a stock FC and the pieces will be stock replacement stuff designed to work together. It will also save me about 1000 dollars for fuel cell, pump, fuel pressure regulator, and whatnot.